‘Tunnels and Underground Stuctues, Zhao, Shiraw 8 Krishnan (eds) 1© 2000 Taylor & Francis, [SEN 905809 171 6 ‘The use of bulk emulsion explosives at the Mandai underground storage caverns BEOng- SembCorp Construction Pre Limited, Singapore ‘M.Myklatun— Selmer ASA, Norway C.Yeung - Orica Singapore Pte Limited, Singapore ‘A.Labriola—Orica Mining Services, Indonesia ABSTRACT: Bulk emulsion explosives have been used in tunnelling and mining operations ‘worldwide but the first application in Singapore was at the Mandai underground caverns project. ‘The system has many advantages over conventional explosives inthe areas of safety, environ- ‘mental aspects, material storage, charging productivity, blasting performance and overall cost savings. A continuous improvement program to monitor drilling and blasting practices will be ‘examined. The goals of the program are: fo improve safety, health and environmental care; to optimise the driling and blasting pattems; fo determine key performance indicators to allow improvements to be measured; and to reduce the overall cost per cubic metre of rock blasted. The successful implementation of bulk emulsion explosives at the Mandai storage cavers supports their use in future caverns projects. At present, more cavers for various purposes are planned for Singapore in the near future 1 INTRODUCTION Ll History In August, 1999 it was announced that Singapore's Defence Ministry (Mindef) would be com- missioning the construction of underground caverns for storage (Nathan, 1999). The caverns are to be built ina disused granite quarry in Mandai and would save more than 300 hectares by building the depot underground instead of oa the surface. Rock caverns have been constructed around the world for many years. Some of the uses in- clude (Zhao etal, 1995): storage, production, processing, recreation, shelter and repository. 12 Geology ‘The Mandai site lies in the Bukit Timah Granite Formation that is part of a massive igneous batholth of Triassic age in Peninsula Malaysia. The Formation covers approximately 200 k for one third ofthe land area of Singapore The Bukit Timah Granite is of extremely good quality and is a suitable medium forthe con- struction of large underground caverns with spans of up to 60 m with minimum reinforcement (Zhao et al, 1995). 1.3. SembCorp-Selmer-oint Operation ‘The contract to construct the first phase ofthe project was awarded to a joint operation formed between SembCorp Construction Pte. Ltd. and Selmer ASA. The supply of bulk emulsion and all explosives was awarded to Orica Singapore Pe. Ltd 3191.3.1 SembCorp Construction Pre, Lid SembCorp is a major player in turnkey construction, design consultancy, and infrastructure de- velopment both in Singapore and the region. It is the first construction company in Singapore to be certified I$ 9002 and has over 900 employees, 50% of whom are professional and technical Staff. Their in-house design division is a full-fledged multiisciplinary firm with five core dis- ciplines: architecture, civil and structural engineering, mechanical engineering, electrical engi- ‘neering and quantity surveying. ‘SembCorp Construction is a one-stop shop capable of providing a variety of construction services ranging from Master Planning to Detaled Engineering Design and Development, Proj- fect Management and Construction. SembCorp Constniction provides engineering and construc- tion services in the building and infrastructure sectors in more than ten cities across the Asia- Pacific region 132 Selmer ASA ‘Selmer is the leading general contractor in Norway with more than 4700 employees. The com- pany is organised in four business segments: Building, Civil Engineering, Industry and Prop- erty Development. The company was established in 1906 and has executed projects in 38 coun= ‘ties. Ithas been certified according to NS-ISO 9001 since 1994, Selmer was called upon for the Singapore Caverns Project because of their vast tunneling experience. Selmer has constructed 18,000 km of tunnels ~ close to half of all tunnel metres in Norway. A otal of 16 sub-sea road tunnels have been built since 1973, The company has con- structed caverns in rock for various purposes. 13.3 Orica Singapore Pte. Led rica, an Australian owned company, has international experience in mining and tunnelling. In Hong Kong, projects that have used bulk emulsion explosives include (Ngai et al, 1997): the ‘Cheung Ching Tunnel, Mass Transit Rail (MTR), the Kau Shat Wan Explosives Complex, the Island West Transfer Station, and Shafts for the Strategic Sewage Disposal System. ‘The Elgas Underground Storage Facility bas been completed in Port Botany, Sydney and was the first underground storage cavern in Australia (Rodgers, 1999). Over 230 tonnes of Power- bulk™ Drive bulk emulsion were supplied by Orica to remove 140,000 cubie metres of rock. Due to close proximity of industrial and residential areas, precision blasting was required t0 ‘produce vibration levels of less than 2 mm/s atthe surface. 2 ORICA EXPLOSIVES’ BULK EMULSION SYSTEM. 241 Composition of Bulk Emulsion Explosives rica's bulk emulsion explosive, Powerbulk"™ Drive consists of two separate components, both containing no explosive ingredients: ‘© The main component is the emulsion phase, or emulsion precursor (AEMSC, 1999), which consists of fine droplets ofa super-saturated oxidiser solution dispersed in a continuous oil phase. Ammonium nitrate and water are the main ingredients in the oxidiser and the oil phase is a hydrocarbon such as diesel fuel, mineral oil of wax The second component, the gasser solution, consists of chemicals that form gas bubbles ‘when itis mixed with the emulsion phase. The bubbles allow the propagation of a derona- tion by heating rapidly when subjected to a shock wave, for example from the detonation of | primer, An explosive is produced when the gassing solution is mixed with the emulsion phase and gas bubbles are formed which sensitse the mixture. It is important to note that with Orica’s System, the gasser solution is added to the emulsion phase asi is pumped but the mixing only takes place at the end ofthe charging hose. ‘The mixture does not become an explosive until the ‘gassing takes place inthe hole, This i safer than pumping.a pre-sensitised product. 3202.1 Classification of Emulsion Phase Emulsion phase, or emulsion precursors, contain no explosive ingredients. They are relatively insensitive to accidental initiation by shock, friction or mechanical impact under nocmal condi tions of use. The product is classified as an oxidising agent (UN Number 3139, Classification code 5.1) rather than as an explosive. All of Oriea’s emulsion phase compositions fail the UN test for determining whether a material is a lass 1 explosive (UN, 1995), ‘The Australian Explosives Manufacturers Safety Committee (AEMSC), formed in 1994, has published a Code of Good Practice for Emulsion Precursors (AEMSC, 1999), 2.2 Properties of Bulk Emulsion Explosives 22.1 Explosives Energy ‘AS mentioned previously, emulsion phase consists of fine droplets ofa super-saturated oxidiser solution dispersed in a continuous oil phase. The microdroplets are forced together, producing a close physical intimacy between the oxidiser and the fuel. This provides a very efficient reac- tion when the emulsion explosive detonates, leading to a high Velocity of Detonation (VOD), ‘This property allows the potential to reduce the numberof drilled holes inthe face compared to pattern drilled for a weaker explosive, such as ANFO. ‘Compared to ANFO, emulsions are characterized by a higher shock to gas energy rato. Its ‘generally believed that shock energy is responsible forthe initial fracturing of the rock, while ‘bas energy is responsible for penetrating existing cracks and fractures and is used to heave bro= keen rock 222 Variable density Iris possible to vary the final density of the emulsion explosive between 0.8 and 1.2 glee by adding different gassing agents to the emulsion phase. This allows a range of options from a single emulsion phase source. The explosive density and energy can be matched to suit rock conditions to help control vibration levels and blast damage, A lower density product is ideal for perimeter control, while the full density formulation can be used where maximum ener required, 2.2.3. Post Blast Fumes ‘The efficiency ofthe chemical reaction when emulsion explosives detonate ensures that the post blast fumes are minimised. This is important wo facilitate quicker re-entry times, and potentially ‘to improve the tunnelling cycle, 2.2.4 Water Resistance Emulsion explosives are composed of a continuous fuel phase that surrounds the droplets of aqueous oxidiser. This fuel phase acts as a barrier to help repel external water and provides a high degree of water resistance to emulsion explosives. This property helps to ensure two things the explosive will detonate as designed, and ‘© the amount of ground water contamination from dissolved explosives will be minimised. 22.5 Handling Characteristics ‘The viscosity of emulsion explosives can be varied from that of grease toa firm putty, allowing its retention during uphole charging. Compared to packaged explosives, the product is fully coupled to the blasthole, increasing the effectiveness of the explosive. 22.6 Technical Properties ‘The properties of Orica’s Powerbulk™ Drive bulk emulsion are shown in Table 1 23. Mobile Charging Unit (MCU) ‘The Orica MCU as shown in Figure 1, consists of several components mounted on an Isuzu four wheel drive truck. The unit uses a power take-off hydraulic system to operate the product ump, stabilising jacks, crane and work basket. 32‘Table. Powerbulk™ Driv Relative Effective Energy" Povwerbul Nominal Density (66) 08 1 M2 REE'- Weight Suength relative 0 ‘Technical Properties Loose poured ANFO = 100% @ 0:8 pee 62% 76% 8% BH 8H: REE! — Bulk Stength relative Loose poured ANFO = 100% @ 0.8 ee 6% 86% 103% 123% 1 Blow loaded ANFO = 100% @ 095 ple 53% 65% 78%—93Y 10086 Caleulated Velocity ofDewnation(VODy 454983 ST OG 1. The Relative Efetive Energy” (REE) ofan explosive isthe energy enleulited wo be avaiable odo efective lasting wor. Its calculated using the Orca eX compute code 2. VOD will depend on conditions of use inching degre of confinement and basthole diameter, ‘The product bopper holds four tonnes of bulk emulsion phase and two piston-type pumps are designed for the efficient delivery of emulsion phase. The product pump design has been proven through extensive testing fo be intrinsically safe under failure conditions including ex- femal fire, deadheading and dry running. Orica operators are also fully trained and certified t0 safely operate all pumps required for the detivery of bulk emulsion explosives inthe blast hole. (Orica’s ICIS™ computer system controls the pumping operation and records relevant hole- by-hole information. The system can accurately control and record the amount of explosive pumped into each hole. It is important to contol overcharging because this can lead to exces sive blast damage as well as contamination of explosives into the ground water. Stored data can, be downloaded to a PC to give a complete writen record ofthe charge-up process, including the ‘exact quantity loaded per hole and summary data such as the total pumping ti used. 3. THE SUPPLY OF BULK EMULSION TO SINGAPORE 3.1. Infrastructure for the Supply of Bull Emulsion Phase In order to supply emulsion phase to Singapore, it was necessary to install a depot on site and to {import an underground vehicle to charge emulsion. Various government approvals were ob- tained and stringent Orica Hazard Studies were conducted before any ground was broken. 3.L.1 Importing a Mobile Charging Unit (MCU) ‘Approval from the Land Transport Authority was required to import che MCU forthe Caverns Project. Tt was necessary for the vehicle to comply with all safety and emissions requirements ‘The hydraulic crane was also tested and approved by the Ministry of Manpower for a safe work- ing load of 200 ky. 3.1.2. Constructing a Storage Depot ‘Approvals from the Ministry of Environment and the Civil Defence Force — Fire Safety Bureau ‘were granted to store emulsion phase on site ‘Orica Explosives performed Hazard Studies on the potential Storage Depot. Hazard Studies are a structured and detailed examination designed to identify and thereby eliminate significant hazards. They are carried out on new and existing plants, processes and facilities, and cover all aspects associated with the design, construction and ongoing operation of the process (including the demolition and decommissioning aspects). Hazard Studies concentrate heavily on mini ing risks to people (employees and the public) and to the environment to acceptable community, statutory and corporate standards 3.2. Logistics of Supplying Emulsion Phase and Packaged Explosives to Singapore ‘The supply of bulk emulsion phase and packaged explosives require the careful scheduling of key individuals who draw from the resources of several countries. All ofthe Orica manufactur- ing sites that supply the Singapore project are ISO 9002 accredited. 322Figure l: Orica's Mobile Charging Unit (MCU) 3.2.1. Emulsion Phase ‘Samples of Orica's emulsion phase, EP Gold™, to be used in Singapore, were sent to the Singa- pporean Arms & Explosives Branch, Department of Scientific Services for analysis. It was con- firmed that the product was not an explosive substance and did not require an explosives licence for its import and export under the Arms and Explosives Act. This property greatly simplified the transporiation, handling and storage requirements of emulsion phase in Singapore. Orica Australia in Gladstone, QLD and Liddell, NSW manufactures bulk emulsion phase. ‘The product is transported by sca in ISO Containers with a capacity of 20 tonnes. Empty con tainers are completely cleaned before they are seat back for refilling. ‘The sailing time from Australia to Singapore is approximately two weeks. 3.2.2 Packaged Explosives (Onica's high energy packaged emulsion explosives Powergel™ 3151 and Trimex®™ 3000 are supplied to Singapore by Orica’ explosives factories in the Philippines and / or Thailand. The ‘eexibilty in sourcing the packaged explosives not only provides the security of supply but also achieves on-time-in-full deliveries o satisfy the project needs 3.23. Initiating Explosives EXEL™ non-electric detonators, CORDTEX™ detonating cord and safety fuse are manufac- tured by Orica Explosives Philippines Inc. Shipping time by sea is approximately one week. 4.1 Ineroduction A joint committee comprising SembCorp, Selmer and Orica personnel was formed to optimize the drilling and blasting operations while maintaining high standards in the areas of Safety, Health and Environment ‘A continuous improvement cycle consists of four steps ‘© Plan—The committee agrees upon some quantifiable key performance indicators. ‘= Do~The respective people implement actions that are agreed upon, ‘© Measure — Several people (Orica, Selmer Foreman, engineers and surveyors) perform measurements. Qualitative observations ar also noted ‘© Improve — The joint committee meets on a regular bass to review and improve. 42 Key Performance Indicators Information was compiled ftom three main sources: Foreman’s Production Report, Daily Charging Report and Daily Surveyor's Report. The data for eight months is summarised in Ta- ble 2. 42.1 Powder Factor Powder Factor is defined as the mass of emulsion in kilograms, used to blast one cubic metre of rock. As shown in Figure 2, the Powder Factor has dropped considerably from th initial fig- ure of 3.63 kim’. The weighted average over the fist eight months was 2.05 kglm’. future ‘goal will be to reduce the numberof holes drilled per face as well as reduce the amount charged per hole. Both ofthese changes will reduce the overall powder factor ofthe blast. 323iling and Charging Statistics. ‘Month Abin Emon Volove Power Fatr gig Rae rll Fas Ding Ras - Cty i) min) (mt) wi on) one saa 3e Nosy 1 et obas 2s aM Ot tek a9 Oe Doo 13 Si) Sle eo 840) I) Lebo bea 20 sas 990 Oks ans Foo ome tasty 19s OM lous Mor 33) am) 9a) coo 51 duis does 5a) Oat 288 ae toyon Mais) iss 2a) tn aan as ss Toni ast 18D 36 WW vet 20s ais tis 220083 * Weighted average: data is weighted by the monthly volume, 42.2. Charging Rate For this study, the charging time beyins only afterall dhe holes are primed (primer is placed at the collar ofthe hole) andthe charging of the first hole with emulsion begins. It ends once the entire face is charged and does not include the time to tie-in the round. The Orica MMU con- tains wo product pumps that operate between 55 ~ 60 ke/ min. During charging, the rate will be significantly lower than this value because dlay is cause by basket positioning, primer in- serion, cleaning of had holes, and deyree of operator experience “The charging rate over the first period is shown in Figures 3 and 4. The charging rate as significantly improved frm te frst month. The weighted average over the first eight months i 14.21 kgimin or 0.15 mia’. These are benchmarks to compare future improvements sgainst and wil be very useful once the charging operation is performed fully by Singaporeans. 423. Drilling Factor ‘The drilling factor isthe length ofall holes drilled in a round divided by the total volume. The chart of dilling factor, in Figute 5, shows thatthe facor has stabilised after the first few ‘months, The weighted average forthe first period is 1.15 mim’. As stated previously a future goal is to reduce the number of holes per round. This will also reduce the drilling factor. 424. Drilling Rate ‘The drilling rate is shown in Figures 6 and 7. The drilling rate varies according to factors such as ground conditions and operator experience. The weighted average forthe first eight months is 220 nmin or 0.53 min’m’. Again, these can be benchmarks from which to gauge further improvements, Powder Factor (k/m®) ‘Charging Rate (kgmin) 400 200 — “PEF ELELE "FPP EPEPE So Figure 2: Powder Factor Values Figure 3: Charging Rate (kg/min) 324‘Charging Rate (minim) Drilling Factor (mim?) oso FILE EEEEFL PLP EEEEE Morn Meth Figure 4: Charging Rate (min/m’) ‘Figure $: Drilling Factor Dring Rate (nmin) Dating Rate (mivm?) 200 | soo! 0 ona - op og) FLL SPSL S FLEEEEEE Meth Morin ‘Figure 6: Drilling Rate (m/min) ‘Figure 7: Drilling Rate (min/m’) 5 CONCLUSIONS The Joint Operation formed between SembCorp Construction and Selmer ASA has made the initial phase ofthe project successful o date. The skills and experience of both companies have been utilised to adapt the Norwegian Tunnelling Technology to Singapore. ‘With Orica’s Bulk Emulsion System, the sensitsing agent is added to the emulsion phase as iis pumped but the mixing only takes place at the end ofthe charging hose. The mixture does not become an explosive until the gassing takes place in the hole. This is safer than pumping pre-sensitised product. ‘Samples of Orica’s emulsion phase were tested by the Singaporean authorities and were con- firmed to be not an explosive substance. Emulsion phase is tansported to, and stored in, Singa- pore asa Class 5.1 Oxidising Agent. ‘Compared to conventional explosives, bulk emulsions explosives ‘+ produce very efficient reactions, with high degree shock energy released during detonation; ‘© can be produced at variable densities during pumping. lighter density product is ideal for wall control while a higher density would be used to fully utilise the explosive energy; ‘© produce minimal post-blast fumes which helps to facilitate quicker re-entry times; ‘+ are very water resistant because the oxidiser phase is coated by a continuous il phase; ‘* ate relatively insensitive to aceidental initiation by shock, friction or mechanical impact un- ‘der normal conditions of use; ‘Table 3. Summary of Key Performance Indicators indicator ‘Weighted Average® Ponder Factor 205 kgin? ‘Charging Rate 14.21 kgiin 0.15 min) Dril Face ‘svn Dring Rate 220 in (0.53 mini’) Veightd average: data is weighted bythe monthly volume forthe period 1099 10 08100. 325Im order to supply the Bulk Emulsion System to Singapore, various approvals were necessary to impor charging vehicle and to st up a storage depot.” The local ovement offices cluded the: Land Transport Authority, Ministry of Manpower, Ministry of Environment, Civil Defence Force ~ Fire Safeiy Butea, and Singapore Police Force = Arms and Explosives Branch. ‘Orica manufacturing sites supply bulk emulsion phase and explosives to the Singapore Cx ems Project from various countries including Ansa, indonesia Philipines and Thailand "A Continvous Improvement Program was formed o optimise the dling and bssting opera tions while maintaining high standards in the areas of Safety, Health and Environment. Key Performance Indicators have been determined forthe Singapore Caverns Projet and ae de played in Table3 forthe first eight months of lasting. ‘The Key Performance Indicator allow benchmarks tobe set which can be used a8 a compari- son for continuovs improvement. This will bcome very weTul once Singaporean operators take over more ofthe tunneling operations fom the Norwesians 6 ACKNOWLEDGEMENTS The authors would like to thank the following organisations for the permission to publish and present this paper: ‘© Defence Science & Technology Agency —Building and Infrastructure, DSTA (BI) ‘© SembCorp Construction Pe. Lid Selmer ASA ‘© Orica Singapore Pte. Ltd. Adgitional thanks go to Jing Chun How for his assistance in compiting and analysing data for the Continuous Tmprovement Program. 7. REFERENCES ‘Australian Explosives Manufacturers Safety Committee (AEMSC) Code of Good Practice Precursor for Explosives Ed, 1 1998 [Nathan,D. 1999, Mindet Goes Underground. 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